Conductive polymer compositions and articles containing same

Abstract

Polymer compositions, which are particularly useful in automotive applications, are described. The polymer composition contain at least one polymer and at least one carbon black having an STSA (statistical thickness surface area) of from about 10 to about 200 m 2 /g, an I 2 No of from about 15 to about 250 mg/g, a tinting strength about 130% or less, a DBPA of from about 20 to about 450 cc/100 g, a CDBP of from about 20 to about 400 cc/100 g, a ratio of I 2 No to STSA of from about 0.4 to about 2.5, a particle size of from about 14 to about 250 nm, and a % volatiles of less than about 5.0%. Articles for automotive applications and other applications, as well as a method for electrostatically painting an article are also disclosed.

1. A method of electrostatic painting an article comprising forming an article comprising a conductive polymer composition and coating at least a portion of said article by electrostatic painting, wherein said conductive polymer composition comprises at least one polymer and at least one carbon black having an STSA of from about 10 to about 200 m 2 /g, an I 2 ZNo of from about 15 to about 250 mg/g, a tinting strength of about 130% or less, a DBPA of from about 20 to about 450 cc/100 g, a CDBP of from about 20 to about 400 cc/100 g, a ratio of I 2 No to STSA of from about 0.4 to about 2.5, a mean particle size of from about 14 to about 250 nm, and a % volatiles of less than about 1.0%, wherein the carbon black comprises from about 5 to about 40% by weight of the conductive polymer composition, and wherein the conductive polymer composition has a volume resistivity of greater than about 100 ohm-cm at room temperature. 
     
     
       2. The method of  claim 1 , wherein the carbon black has an STSA of from about 20 to about 100 m 2 /g, an I 2 No of from about 20 to about 100 m 2 /g, a DBPA of from about 50 to about 300 cc/100 g, and a CDBP of from about 45 to about 250 cc/100 g. 
     
     
       3. The method of  claim 1 , wherein the carbon black has an STSA of from about 20 to about 70 m 2 /g, an I 2 No of from about 20 to about 75 m 2 /g, a DBPA of from about 100 to about 250 cc/100 g, and a CDBP of from about 60 to about 175 cc/100 g. 
     
     
       4. The method of  claim 1 , wherein the carbon black is present in an amount from about 15 to about 30% by weight of the polymer composition. 
     
     
       5. The method of  claim 1 , wherein the carbon black is present in an amount of from about 25 to about 40% by weight of the polymer composition. 
     
     
       6. The method of  claim 1 , wherein the conductive polymer composition has a volume resistivity of greater than about 1000 ohm-cm at room temperature. 
     
     
       7. A method of electrostatic painting an article comprising forming an article comprising a conductive polymer composition and coating at least a portion of said article by electrostatic painting, wherein said conductive polymer composition comprises at least one polymer and at least one carbon black having an STSA of from about 10 to about 200 m 2 /g, an I 2 No of from about 15 to about 250 mg/g, a tinting strength of about 130% or less, a DBPA of from about 20 to about 450 cc/100 g, a CDBP of from about 20 to about 400 cc/100 g, a ratio of I 2 No to STSA of from about 0.4 to about 2.5, a mean particle size of from about 14 to about 250 nm, and a %volatiles of less than about 1.0%, wherein the carbon black comprises from about 5 to about 40% by weight of the conductive polymer composition. 
     
     
       8. The method of  claim 7 , wherein the carbon black has an STSA of from about 20 to about 100 m 2 /g, an I 2 No of from about 20 to about 100 m 2 /g, a DBPA of from about 50 to about 300 cc/100 g, and a CDBP of from about 45 to about 250 cc/100 g. 
     
     
       9. The method of  claim 7 , wherein the carbon black has an STSA of from about 20 to about 70 m 2 /g, an I 2 No of from about 20 to about 75 m 2 /g, a DBPA of from about 100 to about 250 cc/100 g, and a CDBP of from about 60 to about 175 cc/100 g. 
     
     
       10. The method of  claim 7 , wherein the conductive polymer composition has a volume resistivity of greater than about 100 ohm-cm at room temperature. 
     
     
       11. The method of  claim 7 , wherein the conductive polymer composition has a volume resistivity of greater than about 1000 ohm-cm at room temperature. 
     
     
       12. The method of  claim 7 , wherein said carbon black having an STSA of from about 46 to about 56 m 2 /g, an I 2 No of from about 60 to about 70 mg/g, a tinting strength of about 70% or less, a DBPA of from about 137 to about 147 cc/100 g, a CDBP of from about 85 to about 95 cc/100 g, a ratio of I 2 No to STSA of from about 1.2 to about 1.4, a mean particle size of from about 37 to about 47 nm, and a % volatiles of less than about 1.0%, wherein the carbon black is present in an amount of from about 25 to about 40% by weight of the polymer composition. 
     
     
       13. The method of  claim 7 , wherein said carbon black having an STSA of from about 32 to about 42 m 2 /g, an I 2 No of from about 39 to about 49 mg/g, a tinting strength of about 60% or less, a DBPA of from about 112 to about 122 cc/100 g, a CDBP of from about 71 to about 81 cc/100 g, a ratio of I 2 No to STSA of from about 1.1 to about 1.3, a mean particle size of from about 48 to about 58 nm, and a % volatiles of less than about 1.0%, wherein the carbon black is present in an amount of from about 25 to about 40% by weight of the polymer composition. 
     
     
       14. The method of  claim 7 , wherein said carbon black having an STSA of from about 55 to about 65 m 2 /g, an I 2 No of from about 63 to about 73 mg/g, a tinting strength of about 90% or less, a DBPA of from about 121 to about 131 cc/100 g, a CDBP of from about 85 to about 95 cc/100 g, a ratio of I 2 No to STSA of from about 1.05 to about 1.25, a mean particle size of from about 26 to about 36 nm, and a % volatiles of less than about 1.0%, wherein the carbon black is present in an amount of from about 25 to about 40% by weight of the polymer composition. 
     
     
       15. The method of  claim 7 , wherein said carbon black having an STSA of from about 64 to about 74 m 2 /g, an I 2 No of from about 72 to about 82 mg/g, a tinting strength of about 90% or less, a DBPA of from about 188 to about 198 cc/100 g, a CDBP of from about 101 to about 111 cc/100 g, a ratio of I 2 No to STSA of from about 1.05 to about 1.25, a mean particle size of from about 34 to about 44 nm, and a % volatiles of less than about 1.0%, wherein the carbon black is present in an amount from about 25 to about 40% by weight of the polymer composition. 
     
     
       16. The method of  claim 1 , wherein the carbon black is a modified carbon black comprising the carbon black having attached at least one organic group. 
     
     
       17. The method of  claim 1 , wherein the carbon black is treated with a binder resin. 
     
     
       18. The method of  claim 1 , wherein the polymer comprises a polyolefin, a vinylhalide polymer, a vinylidene halide polymer, a perfluorinated polymer, a styrene polymer, an amide polymer, a polycarbonate, a polyester, a polyphenyleneoxide, a polyphenylene ether, a polyketone, a polyacetal, a vinyl alcohol polymer, a polyurethane, or combinations thereof. 
     
     
       19. The method of  claim 7 , wherein the carbon black is a modified carbon black comprising the carbon black having attached at least one organic group. 
     
     
       20. The method of  claim 7 , wherein the carbon black is treated with a binder resin. 
     
     
       21. The method of  claim 7 , wherein the polymer comprises a polyolefin, a vinylhalide polymer, a vinylidene halide polymer, a perfluorinated polymer, a styrene polymer, an amide polymer, a polycarbonate, a polyester, a polyphenyleneoxide, a polyphenylene ether, a polyketone, a polyacetal, a vinyl alcohol polymer, a polyurethane, or a combination thereof. 
     
     
       22. A conductive polymer composition comprising at least one polymer and at least one carbon black, wherein said carbon black has an STSA of from about 46 to about 56 m 2 /g, an I 2 No of from about 60 to about 70 mg/g, a tinting strength of about 70% or less, a DBPA of from about 137 to about 147 cc/100 g, a CDBP of from about 85 to about 95 cc/100 g, a ratio of I 2 No to STSA of from about 1.2 to about 1.4, a mean particle size of from about 37 to about 47 nm, and a % volatiles of less than about 1.0%, wherein the carbon black is present in an amount of from about 25 to about 40% by weight of the polymer composition. 
     
     
       23. A conductive polymer composition comprising at least one polymer and at least one carbon black, wherein said carbon black has an STSA of from about 32 to about 42 m 2 /g, an I 2 No of from about 39 to about 49 mg/g, a tinting strength of about 60% or less, a DBPA of from about 112 to about 122 cc/100 , a CDBP of from about 71 to about 81 cc/100 g, a ratio of I 2 No to STSA of from about 1.1 to about 1.3, a mean particle size of from about 48 to about 58 nm, and a % volatiles of less than about 1.0%, wherein the carbon black is present in an amount of from about 25 to about 40% by weight of the polymer composition. 
     
     
       24. A conductive polymer composition comprising at least one polymer and at least one carbon black, wherein said carbon black has an STSA of from about 55 to about 65 m 2 /g, an I 2 No of from about 63 to about 73 mg/g, a tinting strength of about 90% or less, a DBPA of from about 121 to about 131 cc/100 g, a CDBP of from about 85 to about 95 cc/100 g, a ratio of I 2 No to STSA of from about 1.05 to about 1.25, a mean particle size of from about 26 to about 36 nm, and a % volatiles of less than about 1.0%, wherein the carbon black is present in an amount of from about 25 to about 40% by weight of the polymer composition. 
     
     
       25. The conductive polymer composition of  claim 22 , wherein the conductive polymer composition has a volume resistivity of greater than about 1000 ohm-cm at room temperature. 
     
     
       26. The conductive polymer composition of  claim 23 , wherein the conductive polymer composition has a volume resistivity of greater than about 1000 ohm-cm at room temperature. 
     
     
       27. The conductive polymer composition of  claim 26 , wherein the conductive polymer composition has a volume resistivity of greater than about 1000 ohm-cm at room temperature. 
     
     
       28. The conductive polymer composition of  claim 22 , wherein the carbon black is a modified carbon black comprising the carbon black having attached at least one organic group. 
     
     
       29. The conductive polymer composition of  claim 23 , wherein the carbon black is a modified carbon black comprising the carbon black having attached at least one organic group. 
     
     
       30. The conductive polymer composition of  claim 24 , wherein the carbon black is a modified carbon black comprising the carbon black having attached at least one organic group. 
     
     
       31. The conductive polymer composition of  claim 22 , wherein the carbon black is treated with a binder resin. 
     
     
       32. The conductive polymer composition of  claim 23 , wherein the carbon black is treated with a binder resin. 
     
     
       33. The conductive polymer composition of  claim 24 , wherein the carbon black is treated with a binder resin. 
     
     
       34. The conductive polymer composition of  claim 22 , wherein the polymer comprises a polyolefin, a vinylhalide polymer, a vinylidene halide polymer, a perfluorinated polymer, a styrene polymer, an amide polymer, a polycarbonate, a polyester, a polyphenyleneoxide, a polyphenylene ether, a polyketone, a polyacetal, a vinyl alcohol polymer, a polyurethane, or combinations thereof. 
     
     
       35. The conductive polymer composition of  claim 23 , wherein the polymer comprises a polyolefin, a vinylhalide polymer, a vinylidene halide polymer, a perfluorinated polymer, a styrene polymer, an amide polymer, a polycarbonate, a polyester, a polyphenyleneoxide, a polyphenylene ether, a polyketone, a polyacetal, a vinyl alcohol polymer, a polyurethane, or combinations thereof. 
     
     
       36. The conductive polymer composition of  claim 24 , wherein the polymer comprises a polyolefin, a vinylhalide polymer, a vinylidene halide polymer, a perfluorinated polymer, a styrene polymer an amide polymer, a polycarbonate, a polyester, a polyphenyleneoxide, a polyphenylene ether, a polyketone, a polyacetal, a vinyl alcohol polymer, a polyurethane, or combinations thereof. 
     
     
       37. A conductive polymer composition comprising at least one polymer and at least one carbon black, wherein said carbon black has an STSA of from about 64 to about 74 m 2  g, an I 2 No of from about 72 to about 82 mg/g, a tinting strength of about 90% or less, a DBPA of from about 188 to about 198 cc/100 g, a CDBP of from about 101 to about 111 cc/100 g, a ratio of I 2 No to STSA of from about 1.05 to about 1.25, a mean particle size of from about 34 to about 44 nm, and a % volatiles of less than about 1.0%, wherein the carbon black is present in an amount from about 25 to about 40% by weight of the polymer composition. 
     
     
       38. The conductive polymer composition of  claim 37 , wherein the conductive polymer composition has a volume resistivity of greater than about 1000 ohm-cm at room temperature. 
     
     
       39. The conductive polymer composition  37 , wherein the carbon black is a modified carbon black comprising the carbon black having attached at least one organic group. 
     
     
       40. The conductive polymer composition of  claim 37 , wherein the carbon black is treated with a binder resin. 
     
     
       41. The conductive polymer composition of  claim 37 , wherein the polymer comprises a polyolefin, a vinylhalide polymer, a vinylidene halide polymer, a perfluorinated polymer, a styrene polymer, an amide polymer, a polycarbonate, a polyester, a polyphenyleneoxide, a polyphenylene ether, a polyketone, a polyacetal, a vinyl alcohol polymer, a polyurethan, or combinations thereof. 
     
     
       42. An article comprising the conductive polymer composition of  claim 22 . 
     
     
       43. An article comprising the conductive polymer composition of  claim 23 . 
     
     
       44. An article comprising the conductive polymer composition of  claim 24 . 
     
     
       45. The article of  claim 42 , wherein the article is a component of an automobile fuel system. 
     
     
       46. The article of  claim 42 , wherein the article is electrostatically painted. 
     
     
       47. The article of  claim 43 , wherein the article is a component of an automobile fuel system. 
     
     
       48. An article comprising the conductive polymer composition of  claim 37 . 
     
     
       49. The article of  claim 48 , wherein the article is a component of an automobile fuel system. 
     
     
       50. The article of  claim 48 , wherein the article is electrostatically painted. 
     
     
       51. The article of  claim 43 , wherein the article is electrostatically painted. 
     
     
       52. The article of  claim 44 , wherein the article is a component of an automobile fuel system. 
     
     
       53. The article of  claim 44 , wherein the article is electrostatically painted.